Apparatus for automatically winding concentric dynamoelectric machine coils

ABSTRACT

Apparatus for automatically winding a set of at least two concentric dynamoelectric machine coils upon a coil form having at least two progressively small steps. A flyer for winding wire on the coil form steps is rotatably supported by a block, and a two-speed electric motor is connected to rotate the flyer. A slide supports the block and flyer for longitudinal movement parallel with the axis of the flyer between forward and rear positions, and latches selectively retain the block and flyer at the forward and at least one intermediate position thereby to locate the flyer in winding relationship with each of the coil form steps. The slide with the block and flyer supported thereon is mounted for longitudinal movement thereby to traverse the flyer across the coil form steps. In one embodiment the slide is oscillated by the motor thereby to level-wind the wire on each of the coil form steps; and in another embodiment the slide is continuously moved from a forward to a rear position by a lead screw driven by the motor. A control circuit is provided which automatically actuates the motor to its low speed a predetermined number of turns in advance of completion of a given coil; and which upon completion of the coil actuates a latch to permit the block and flyer to move rearwardly by one incremental step when the flyer is in a predetermined rotational position with respect to the coil form, thereby to move the flyer into winding relationship with the next coil form step, and actuates the motor to its high speed to initiate winding of the next coil. The motor is preferably a multiphase, two-speed, constant torque induction motor, thus providing very rapid acceleration and deceleration between its high and low speeds, and the latches are preferably electromagnetically actuated from a source of substantially ripple-free direct current, thus providing nearly instantaneous stepping of the flyer, to the end that a set of concentric coils may be automatically wound at high speed without stopping the flyer and with the connections between adjacent coils accurately located.

United States Patent [72] Inventor Robert,].Eminger Fort Wayne, Ind.

[21] Appl. No. 811,016

[22] Filed Mar. 27, 1969 [45] Patented May 11, 1971 [73] Assignee FortWayne Tool & Die, Inc.

Fort Wayne, Ind.

[54] APPARATUS FOR AUTOMATICALLY WINDING CONCENTRIC DYNAMOELECTRICMACHINE [50] Field of Search [56] References Cited UNITED STATES PATENTS2,736,346 2/1956 Ammann l40/92.1 2,7 82,809 2/1957 Smallridge 140/92. 12,934,099 4/1960 Mason..... 140/92.1 3,036,603 5/1962 Moore.. 140/92. 13,151,638 10/1964 Hill 140/92.l

Primary ExaminerLowell A. Larson Attorney-Hood, Gust, Irish & LundyABSTRACT: Apparatus for automatically winding a set of at CLUTCH STOPSTEP COMMUTA ORS COMMUTATORS FWD. RVS FWD.

least two concentric dynamoelectric machine coils upon a coil formhaving at least two progressively small steps. A flyer for winding wireon the coil form steps is rotatably supported by a block, and atwo-speed electric motor is connected to rotate the flyer. A slidesupports the block and flyer for longitudinal movement parallel with theaxis of the flyer between forward and rear positions, and latchesselectively retain the block and flyer at the forward and at least oneintermediate position thereby to locate the flyer in windingrelationship with each of the coil form steps. The slide with the blockand flyer supported thereon is mounted for longitudinal movement therebyto traverse the flyer across the coil form steps. In one embodiment theslide is oscillated by the motor thereby to level-wind the wire on eachof the coil form steps; and in another embodiment the slide iscontinuously moved from a forward to a rear position by a lead screwdriven by the motor. A control circuit is provided which automaticallyactuates the motor to its low speed a predetermined number of turns inadvance of completion of a given coil; and which upon completion of thecoil actuates a latch to permit the block and flyer to move rearwardlyby one incremental step when the flyer is in a predetermined rotationalposition with respect to the coil form, thereby to move the flyer intowinding relationship with the next coil form step, and actuates themotor to its high speed to initiate winding of the next coil. The motoris preferably a multiphase, two-speed, constant torque induction motor,thus providing very rapid acceleration and deceleration between its highand low speeds, and the latches are preferably electromagneticallyactuated from a source of substantially ripple-free direct current, thusproviding nearly instantaneous stepping of the flyer, to the end that aset of concentric coils may be automatically wound at high speed withoutstopping the flyer and with the connections between adjacent coilsaccurately located.

RVS.

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"TPPLY VACUUM BRA E ENERG. EXTEND CENTERING CYL. Q QS Q- Q EE REMOVEVACUUM L EJECT APPLY VACUUM TAPE .REMOVE COILS LS9 CLOSED EXTEND COILEXTEND TAPE CYL. CUT-OFF- CLOSE LS6 FORM RETRACT COLLAPSE TAPE CYL.

INACTIVE COIL." FORM I 's4 CLOSED INDE I L 7" OSED L s kTUATED REVERSESTART 4 MOTOR HIGH I INvENToR. ROBERT] J.. E vIINGER ATTORNEYS PATENTEUam 1 I97! 7 3.578.034 sum user" 12 4 IE1 FLY-ER DRIVE MOTOR CONSTANT 3M0f TORQUE INDEX 32* INDEX DRIVE MOTOR CONTACTS START-I MH STOP T FLYER115 T' E n WHBH SPEED v I 'TRl-2 FLYER W LOW SPEED L :Wf FLYER FORWARD li 04 Eff FLYER REVERSE i 7 CR2 3: SOL.'A RETRACT l RSTARTZ Tfi CENTERINGP l CYLINDER 5 TR WAUTOMATIC CYCLE CRIS-l 9515 TR5-2 ,CRl4-l a u LSI 1 2CLUTCH START & RUN %E PF i'-'PED AND/96202.

BRAKE COUNTER CONTROL CL EARLY WARNING FLYER SLOW cR|s-2' RR2-| CLl-I vT cuz I INVENTER- ROBERT J. EMINGER ATTORNEYS PATENTEIIIIIYI I III SHEET12 OF LS R CLOSED ISTEP WIND wIND EEE E a T MOTOR s Dw HIGH SPEED STOPLATCH LATCH EARLY CLUTCH DEENERG. RETRACT WARNING BRAKE ENERG. RIGHTMOTOR EXTEND CENTERINGCYL. LATCH SLOW LS3 ACTUATED START. RETRACT BOTHLATCHES MOTOR HIGH BLOCK TO REAR PosITIoN L5 4 5 I2 LSIO AGTuATED cLooRELEAsE LEAD SCREW NUT RETRACT LSII ACTUATED NTER N6 RETURN sLIDE CE ESII; L%%*ED EXTEND oRIENTING CYL. CLUTCH ENERG. REMOVE COILS EXTENDcoLLARsE MOLD INACTIVE MOLD I I I RETuRN CARRIER AND INDEX A I LSI2GLo'sED EXTEND BOTH LATCHES ENGAGE LEAD SCREW NUT LsII DEACT RETuRNBLOCK LS4 CLOSED INvENToR BERT J. EMINGER Y MMNOLAALZ ATTORNEYSAPPARATUS FOR AUTOMATICALLY WINDING CONCENTRIC DYNAMOELECTRIC' MACHINECOILS BACKGROUND OF THE INVENTION 1. Field of the Invention Thisinvention relates generally to prewinders for winding dynamoelectricmachine coils prior to insertion of the coils in a core member, and moreparticularly to apparatus for automatically winding a set of at leasttwo concentric dynamoelectric concentric coils.

2. Description of the Prior Art Flyer-type prewinders have been providedfor winding concentric dynamoelectric machine coils upon a coil formhaving axially extending steps of progressively smaller size. In oneconventional form of such prior prewinder, the flyer is initiallypositioned in winding relationship with the first coil form step andthen oscillated as it is rotated to level-wind a coil on the first step.At the conclusion of winding the first coil, the flyer is stopped,rotated a partial turn as required to a predetermined rotationalposition with respect to the coil fonn, moved axially to position theflyer in winding relationship with the next coil form step, and thenagain rotated and oscillated so as to wind the next coil. It will bereadily apparent that the requirement that the flyer be stoppedcompletely during its incremental movement from winding relationshipwith one coil form step to the next places a practical lower limit uponthe total time required for winding a set of coils, even though theflyer is operated at relatively high speed during the winding of eachcoil. Efiorts to shift the flyer from one coil form step to the nextwithout stopping the flyer have met with difficulty due to therequirement that the connection between adjacent coils be accuratelylocated at predetermined positions, thus requiring that the flyer beshifted when it is in a predetermined rotational position with respectto the coil form.

SUMMARY OF THE INVENTION In application Ser. No. 813,798 of the presentinventor, and assigned to the assignee of the present application, thereis disclosed flyer-type apparatus for winding concentric dynamoelectricmachine coils in which the requisite accurate location of theconnections between the coils is maintained without stopping the flyerduring shifting from one coil form step to the 'next. In order to wind aset of concentric dynamoelectric machine coils, i.e. the coilscomprising one pole of a dynamoelectric field winding, without stoppingthe flyer between coils while still preserving the requisite accuratepositioning of the inner-coil-connections, it is necessary that therotational speed of the flyer be rapidly reduced from a higher windingspeed to a lower but constant speed immediately prior to completion ofthe particular coil, and that the flyer be nearly instantaneouslyshifted from one coil form step to the next, the shift occurring whenthe flyer is in the predetermined rotational position with respect tothe coil form.

In accordance with the invention, the requisite rapid deceleration andacceleration between higher and lower constant speeds is obtained by theuse of a two-speed, alternating current induction motor, decelerationfrom the .higherwinding speed to the lower flyer-shifting speed, such asfrom 3,000 to 1,500 rpm, thus being accomplished in two or threerevolutions of the flyer. Further, the requisite nearlyinstantaneousshifting of the flyer is accomplished by electromagnetically actuatedlatches energized by substantially ripplefree direct current in responseto means which senses the rotai tional position of the flyer withrespect to the coil form.

It is further desirable to provide for automatically winding all of thepoles of a dynamoelectric machine field winding, whichnecessitatesindexing the coil-form upon completion of. the coils of each pole. Itfurther may be required that the direction of rotation of the flyer bereversed for winding the coils of each successive poles. Still further,it may be desirable automatically to apply adhesive tape to a coil formfor retaining the coils wound thereon in their completed form. Theapparatus of the present invention automatically performs theseadditional operations.

Thus, the invention in its broader aspects provides acoil form havingspaced opposite ends with at least two progressively smaller stepsextending therebetween. A flyer is provided mounted on a shaft forwinding a wire on the coil form steps to form the coil, and first meansare provided for rotatably supporting the shaft. An electric motor isprovided having at least two speeds, the motor being coupled to theshaft for rotating the same and the flyer, and a control circuit isprovidedincluding first control means for selectively energizing themotor for high and low speed operation. Second means is provided forsupporting the first support means, and the shaft and flyer forlongitudinal movement parallel with the axis of the shaft, and firstmeans is provided on the second support means and operatively connectedto the first support means for selectively, sequentially moving thefirst support means, shaft and flyer from a forward'to a rear positionin at least one incremental step thereby respectively to position theflyer in winding relationship with the coil form steps. Second means isprovided operatively coupling the motor to the second support means formoving the same and the first sup- "port means, shaft and flyerlongitudinally parallel with the axis of the shaft thereby to traversethe flyer with respect to the coil form. Means are provided forselectively positioning the first support means, shaft and fiyer at aninitial location with the first support means in its forward positionand with the flyer in winding relationship with the coil form stepadjacent one end of the coil form; Means are provided for counting thenumber of revolutions of the shaft and flyer thereby to .count thenumber of turns of the respective coils. Means are provided forinitially actuating the first control means to energize the motor forhigh speed operation thereby to wind 21 first coil on a first coil formstep at high speed. The control circuit further includes second controlmeans responsive to the counting means for actuating the first controlmeans to energize the motor for low speed operation in response towinding a first predetermined number of turns of the first coil, andthird control means responsive to the counting means foractuating thefirst moving means to move the first support means, shaft and flyer by afirst incremental step from-its forward position to a second position.with the flyer located in winding relationship with the second coilform step adjacent the first coil form step in response to a secondpredetermined 'number of turns of. the first coil greater than the firstnumber and corresponding to completion of the first coil. The 'thirdcontrol means is coupled to the first control means and actuates thesameto energize the motor for high speed operation in response to thesecond number thereby to initiate winding of a second coil on the secondcoil form step at high speed.

It is accordingly an object of the present invention to provide improvedapparatus for automatically winding a set of at least two concentricdynamoelectric coils.

Another object of the present invention is to provide improvedflyer-type apparatus for automatically winding a set of at least twoconcentric dynamoelectric coils without stopping the-rotation of theflyer between coils.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. I is a diagrammatic illustrationof one embodiment of the invention in which each coil is level-woundupon the respective coil form step, and further illustrating thecoilformindexing and adhesive tape-applying features of the invention;FIG. 2 is a circuit diagram illustrating the automatic control system ofthe apparatus of FIG. 1;

FIG. 3 is a timing diagram useful in explaining .the cycle of operationof the apparatus of FIGS. 1 and 2;

" FIG. 4 diagrammatically illustrates a second embodiment of theinvention in which the coils are single layer-wound upon the coil forms;

FIG. 5 is a circuit diagram schematically illustrating theautomaticcontrol system for the apparatus of H04; and

P10. 6 is a timing diagram useful in explaining the cycle of operationof the apparatus of FIGS. 4 and 5.

DESCRIPTION OF THE PREFERRED EMBODlMENTS Level-Wind Embodiment Referringnow to H6. 1 of the drawings, the apparatus of the invention forautomatically level-winding concentric dynamoelectric machine coils,generally indicated at 10, comprises a flyer winder assembly 12, a coilform assembly 14, and an adhesive tape-applying assembly 16. Coil formassembly 14 14 comprises a block 18 having a plurality of stepped,radially displaced, collapsible coil forms 20 thereon. In theillustrated embodiment, coil form assembly 14 has four coil forms 20thereon equally spaced around block 18 by 90, only three of which 20-1,20-2 and 20-3 are shown. Each of the coil forms 20 is shown ascomprising four steps 22-1, 22-2, 22-3 and 22-4, the forward steps 22-1and 22-2 having a first axial length and the rear steps 22-3 and 22-4having a second, shorter axial length, As used herein, forward" refersto a direction extending toward the block 18, whereas rear" and rearwardrefer to a direction extending toward the flyer assembly 12.

Block 18 and the stepped coil forms 20 supported thereon are mounted forrotational movement by means of a shaft 24 joumaled in a frame element26. Shaft 24, block 18 and coil forms 20 are rotated thereby to indexthe coil forms from one position to the next by means of gear 28 andshaft 24 driven by pinion 30 on the shaft of a suitable index motor 32.In the embodiment illustrated in FIG. 1, coil form 20-1 is shown at awinding station, coil form 20-2 is at an unloading station, and coilform 2.0-3 is at a tape applying station. the fourth coil formdiametrically opposite coil form 20-2 being at an inactive station.

Each of the coil forms 20 comprises an upper, fixed part 34 and a lowermovable part 36. The two parts 34, 36 are normally retained in theirexpanded position by suitable springs 38. The coil forms are collapsedby extension of piston rod 40 of a conventional pneumatic cylinder 42supported on frame element 26, extension of piston rod 40 engaging themovable part 36 of the respective coii form 20 and moving it upwardlyagainst spring 38 thereby collapsing the respective coil form so as topermit removal of the coils therefrom. For illustrative purposes,cylinder 42 is shown in FIG. 1 as being located to collapse coil form20-3 at the tape-applying station, however it will be understood that ifthe coil unloading station is located intermediate the winding andtape-applying stations, cylinder 42 would be located in alignment withcoil form 20-2. A suitable limit switch, identified as LS5, sensesretrac tion and extension of piston rod 40 of cylinder 42, and thusextension and collapse respectively, of the respective coil form 20, aswill be hereinafter more fully described. A suitable cam 44 driven byshaft 24 cooperates with a suitable limit switch, identified as LS7, toprovide an indication of proper positioning of the coil forms 20 witheach of the coil forms at a respective station.

Flyer apparatus 12 comprises a conventional flyer 46 for winding thewire 48 on the respective coil form step 22 of the coil form 20 at thewinding station. Flyer 46 is mounted on a splined shaft 48 supported forrotational and axial movement by suitable bearings mounted on frameelements 50 and 52. Shaft 48 and flyer 46 are rotatably driven by meansof pulley 54 having a splined connection with shaft 48. Pulley 54 is, inturn, driven by belt 56 and pulley 58 on shaft 60. Shaft 60 and pulley58 are driven by a two-speed, constant torque, reversible, three-phase,alternating current, induction motor 62 through a conventionalclutch-brake 64, as will hereinafter be described.

The end of splined shaft 48 remote from flyer 46 is rotatably attachedto projection 66 on block 68. Projection 66 extends downwardly through aslot 70 in slide 72 which supports block 68 for longitudinal movement ina direction parallel with the axis of shaft 48 between forward and rearpositions defined,

respectively, by the limit switches identified as LS4 and LS2, block 68being shown in its forward position in FIG. 1 with flyer 46 thus locatedin winding relationship with the largest step 22-1 of the respectivecoil form 20 adjacent block 18. It will thus be seen that rearwardmovement of block 68 will be accompanied by rearward movement of splinedshaft 48 and flyer 46 in the direction shown by the arrow 74.

It will be readily understood that splined shaft 48 has an axiallyextending opening therethrough through which wire 49 extends, the wirethus being withdrawn from a conventional supply shown by the dashedlines 76.

A conventional pneumatic cylinder 78 is mounted on slide 72 and has itspiston rod 80 connected to block 68. A suitable solenoid valve,identified as solenoid F is coupled to cylinder 78 and normally actuatesthe same to bias block 68, splined shaft 48 and flyer 46 MH in thedirection as shown by the arrow 74. Rearward movement of block 68, shaft48 and flyer 46 is selectively restrained by a pair of latch members 82and 84 pivotally mounted on slide 72 and cooperatively engagingabutments 86, 88, 90 and 92 on block 68. in the illustrated embodiment,abutments 86, 88, 90 and 92 are respectively axially spaced apart onblock 68 by distances corresponding to the respective axial lengths ofthe steps 22-1, 22-2, 22-3 and 22-4 of the coil forms 20. lt will beobserved that with block 68 in its forward position as shown in F IG. 1,latch 82 engages abutment 86 thereby retaining block 68 in its forwardposition, thus locating flyer 46 in winding relationship with theforward coil form step 22-1.

Latches 82, 84 are respectively actuated by conventional pneumaticcylinders 87, 89 mounted on slide 72, cylinders 87 89 in turn beingrespectively actuated by solenoid valves respectively identified assolenoid C and solenoid D. Thus, it will be seen that actuation ofsolenoid C and cylinder 87 will pivot latch 82, referred to as the rightlatch" away from abutment 86 with the result that cylinder 78 will moveblock 68, splined shaft 48 and flyer 46 rearwardly in the directionshown by arrow 74 until abutment 88 engages latch 84, thereby locatingflyer 46 in winding relationship with the next coil form step 22-2.Similarly, actuation of solenoid D and cylinder 89 will result inpivotal movement of latch 84, referred to as the left latch" away fromabutment 88 so that cylinder 78 moves block 68, splined shaft 48 andflyer 46 rearwardly until latch 82 engages abutment 90, thereby locatingflyer 46 in winding relationship with the next coil form step 22-3.Finally, actuation of solenoid C and cylinder 87 will result in pivotalmovement of latch 82 away from abutment 90 with the result in pivotalmovement of latch 82 away from abutment 90 with the result that cylinder78 will move block 68, splined shaft 48 and flyer 46 move rearwardlyuntil latch 84 engages abutment 92 with flyer 46 thus located in windingrelationship with the smallest coil form step 22-4. As will hereinafterbe described, actuation of solenoid F will reverse the application ofair to cylinder 78 thereby to return block 68, splined shaft 48 andflyer 46 from its rear position to its forward position, in thedirection shown by the arrow 90,

thereby again to locate flyer 46 in winding relationship with thelargest coil form step 22-1.

As indicated above, it is important that the axial stepping of flyer 46from one coil form step to the next be accomplished nearlyinstantaneously, which in turn requires extremely rapid actuation oflatches 82, 84 by pneumatic cylinders 87, 89 Rapid actuation of apneumatic cylinder is inhibited by the presence of moisture and/or oilin the high pressure air supplied thereto. Thus, in accordance with theinvention, solenoids C and D are coupled to high pressure air supplyline 92 by a suitable filter 94 for removing moisture and oil from thehigh pressure air. it will be readily understood that cylinders 87 89are of the air-actuated, spring return type. Thus, actuation of arespective solenoid valve C or D will admit high pressure air to therespective cylinder to retract its piston rod, thus pivoting therespective latch 82, 84 out of engagement with the respective abutment,while deactuation of the respective solenoid valve C or D therebyterminating the application of high pressure air will result inimmediate extension of the piston rod, of the respectivecylinderunderthe influence of its internal spring. thereby immediatelyto. return the respective latch 82, 84 to its restraining position.

The slide 72 is mounted for axial movement parallel with the axis ofshaft 48 by means of suitable rails 96 mounted on frame element 98.Slide 72 is moved. axially in'oscillatory fashion, as shown by the arrow100, by mechanism. 102 now to be described which provides two differentaxial lengths of coil form steps 22-1, 22-2, and 22-3, 22-4. Thus,- withblock-68, splined shaft 48, and flyer 46 positioned, as above-described,with flyer 46 in winding relationship with either of the longer coilform steps 22-1 or 22-2, oscillation of slide 72 with the longer of itstwo throws via mechanism 102 will result-in corresponding oscillation ofblock68, splined shaft 48 and flyer 46 thereby to level-wind wire 49 onthe respective coiluform step 22-1 or 22-2. Similarly, with block68,shaft 48 and flyer 46 positioned with flyer 46 located in windingrelationship. with either of the shorter coil form steps 22-3 or 22-4,oscillation of slide 72 with its shorter throw via, mechanism 102 willresult in oscillation of block 68, splined shaft 48-and flyer 46 therebyto level-wind wire 49 on the respective shortercoil form step 22-3 or22-4.

Throw shift mechanism 102 comprises'a lever member 104 pivotallyconnected to bracket 106. Pivoted lever 104 has oneslotted end 108coupled to slide 72 and its opposite slotted end 110 coupled toactuating member 112. Bracket 106 is connected to piston'rod 114 ofpneumatic cylinder 116 actuated by a solenoid valve, identified assolenoid]. Actuating member 112 is oscillated reciprocally by means of aheart shaped cam 118 cooperating with a cam follower120. on member 112.Heart-shaped cam is driven by aselectivelyavariable speed drive 122which, in turn, is driven by driveshaft 60. Cam follower 120 is normallybiased into engagement with heart-shaped cam 118 by extension of pistonrod 124 of pneumatic cylinder 126. It will thus be seen that thereciprocal motion imparted to actuating member 112 by rotation ofheart-. shaped cam 118 will result in the reciprocal oscillatory motionof slide 72 with a throw depending upon the position I of pivoted lever104. Lever 104 is shown in its lower position in FIG. 1 with piston rod114 of cylinder 116 retracted, thus imparting the longer throw to theoscillatory motion of slide 72 for level-winding the coils on the longercoil form steps 22-1 and 22-2. It will further be seen that theextension of piston rod 114 of cylinder 116 responsive to actuation ofsolenoid I will move pivoted lever 104 to its upper position therebyproviding the shorter throw for slide 72 for level-winding coils on theshorter coil form steps 22-3 and 22-4. It will be readily.

understood that the throw-selecting mechanism 106', 114, 116 with thethrow-selecting solenoid J may be eliminated where the coil form steps22 are all of the same axial length.

As will hereinafter be more fully described, it is desirable that closeto the end of winding a coil on a respective .coil form step, the flyer46 be moved axially rearwardly from whatever ing slide 72 to the rearextremity of its throw so as to position flyer 46 adjacent the rear endof the respective coil form step. Deactuation of solenoid B reverses theapplication of high pressure air to cylinder 126 so as to bias itspiston rod 124 outwardly again to urge cam follower 120 into engagementwith its heart-shaped cam 118.

As indicated above, it is desired that the connections between adjacentcoils wound on-the coil form steps 22beaccurately located atpredetermined positions, and thus it'is desired that the flyer 46 have apredetermined rotational position with respect to the respective coilform when it is moved rearwardly by an incremental step into windingrelationship with the next smaller coil form step. Further, it isdesired that the flyer haveapredetermined rotational position withrespect to the respective coil form 20 upon completion of a respectiveset of coils. These predetermined rotational positions may be atdifferent locations for the forward and reverse directions of rotationof flyer 46.

In order to provide for stepping and stopping of flyer 46 at the desiredrotational position with respect to the respective coil form 20 in eachdirection of rotation, a timing shaft 130 is provided driven from shaft20 by appropriate pulleys and belt 132. Forward and reverse steppingcommutators 134, 136, and forward and reverse stopping commutators 138,140 are mounted on shaft 13.0 and with cooperating contacts controlthetiming of the stepping and stopping operations, as will behereinafter-described. It will be understood that timing-shaft 130 isdriven at the same rotational speed as flyer 46. The

number of revolutions of flyer 46 and thus thenumber of turns wound uponthe respective coil form steps 22 are counted by a conventional counter142 which counts the number of revolutionsof timing shaft by means of aconventional photoelectric device 144. Counter 142 is conventional andincludes appropriate means for presetting the number of turns to bewound on each of the coils of the set, four as shown in FIG. 1, and thusprovides a signal across its tum-completion output terminals 146 inresponse to completion of the predetermined number of turns in eachofthe coils. Further, counter 142 provides across its early warningterminals 148 a signal a predetermined number of turns in advance ofcompletion of a respective. coil, such as four turns that signalpersisting until completion of the respective coil.

It is further desired positively to rotationally locate the flyer 46.and timing shaft 130 prior-to commencement of winding each new set ofcoils. In order to provide this positiverotationallocation, a centeringdisc 150 is provided on the end of timing shaft 130 and havingdiametrically oppositerollers 152 projecting therefrom. A pivoted levermember 154 is provided actuated by a piston rod 156 of pneumaticcylinder 158. Actuation of a solenoid valve, identified as solenoid Aprovides retraction of piston rod 156 and movement of lever member 154away from cooperative engagement with rollers 152, whereas actuation ofa solenoid valve, identified as solenoid E results in extension ofpiston rod 156 and movement of lever member 154 into cooperativeengagement with rollers 152. It will readily be seen that if thedisc 150is rotationally positioned so that rollers 152 are located as shown bythe dashed lines, extension'of piston rod 156 and radially inward move.-ment of pivoted lever member 154 will result in engagement of levermember 154 with one or the other of the rollers 152 thereby positivelyto rotate disc 150, to the positionshown in FIG. 1, thereby-rotatingvtiming shaft 130, splined shaft 48 and flyer 46to the desired rotationalposition. The retracted and extended positions of piston rod 156 ofcentering cylinder 158, and thus the retracted and extended positions ofpivoted lever member 154 are sensed 'by limit'switches identified as LS1and LS3 respectively. Reversing of motor 62 and thus the direction ofrotation of flyer 46 for winding successive sets of coils in oppositedirections is controlled'by-a suitable cam 160 on index shaft 24, and acooperating limit switch, identified as LS8.

In order to provide for the application of adhesive tape to the coilforms 20 prior to the winding of coils thereon, and for retention of thetape thereon until winding of at least some of the coils, each .of thecoil forms 20 has an axially extending, upwardly facing slot 162 formedin its upper part 34. Each of the slots- 162 has a vacuum conduit 164communicating therewith, only one of which is shown in FIG. 1. The fourvacuum conduits 164 extend downwardly through index shaft Tape applyingmechanism 16 comprises a source 170 of tape 172 having adhesive on itsouter side 174, ie. the side which faces outwardly when the tape ispositioned in slot 162, so that the tape will adhere to the undersurfaces of the turns of wire forming the coils. A suitable length oftape 172 is injected into the slot 162 by rollers 176 driven by gear 178and cooperative rack 180. Rack 180 is in turn actuated by a pneumaticcylinder 182 which, in turn, is actuated by a suitable solenoid valve,identified as solenoid H. Retraction of rack 180 by cylinder 182 resultsin ejection of tape 172 by rollers 176 into the slot 162. Return of rack180 to its extended position, as shown in H0. 1 actuates cutoffmechanism 184 to sever tape 172. The retracted and extended positions oftape ejection cylinder 182 and rack 180 are respectively sensed by limitswitches LS6 and LS9.

Referring now additionally to FIG. 2, the flyer drive motor 62, which asindicated is preferably a two-speed, constant torque, three-phase,alternating current induction motor, is energized from a source 186 ofthree-phase alternating current, by reversing contacts MF and MR, and byhigh and low speed contacts MH and ML. index drive motor 32, which mayalso be a conventional three-phase, alternating current induction motor,is energized from source 186 through contact Ml. Lines 188, 190 ofcontrol circuit 192 are energized by control transformer 194 from onephase of source 186.

it will now be assumed that the apparatus of FIG. 1 is positioned toinitiate winding of a set of coils on coil form 20-1, bloclr. 68 beingin its forward position thus locating flyer 46 in winding relationshipwith the largest coil form step 22-1. in this preliminary condition ofthe apparatus, centering cylinder 158 is extended thus retaining flyer46 in the desired position against accidental displacement. Further, inthis condition, solenoid B is deenergized and the piston rod 124 oflevel wind cylinder 126 is extended to urge cam follower roller 120against heart-shaped cam 118.

Rectifier 196 coupled across control lines 188, 190 supplies directcurrent to lines 198, 200 and solenoid 202 of clutchbrake 64 isenergized through normally closed time delay relay contacts TR2-D1 andnormally closed relay contacts CR-2. Manually actuated START switch 204is now momentarily depressed, simultaneously momentarily closing START-1and START-2 switch contacts. Closing START-1 switch contacts energizesthe operating coil of the high speed contacts MH through the normallyclosed STOP switch and the normally closed contacts of relay TRl-l. Theoperating coil of the forward contacts MP is also energized through thenormally closed contacts of control relay CRlO-l, and the operating coilof control relay CR2 is energized closing its contacts CR2-1 to seal-inthe MH MF and CR2 operating coils. Drive motor 62 is thus energized atits high speed in the forward direction.

Energization of control relay CR2 also closes its contacts CR2-2 andthus momentary closing of the START-2 switch contacts energizes solenoidA through nonnally closed control relay contacts CRS-l thereby toretract the centering cylinder 158. Upon closing of limit switch LS1responsive to retraction of centering cylinder 158, the operating coilof time delay relay TR3 is energized through normally closed relaycontact CR-2.

Energization of the TR3 operating coil immediately closes its contactsTR3-1 thereby energizing the operating coil of control relay CR throughthe normally closed time delay contacts TR3-D, which open after apredetermined time delay following energization of the TR3 operatingcoil. Energization of coil relay CR closes its contacts CR-l thusscaling in the CR operating coil through the non'nally closed steppingreed relay contact RR1-1. Closing of control relay contact CR-lenergizes the clutch solenoid 204, and simultaneous opening of contactsCR-Z deenergizes the brake coil 202. With the clutch portion ofclutch-brake 64 thus energized, flyer 46 is rotated at high speedthereby to wind the first coil on the largest coil form step 22-1, asabove-described.

Referring briefly to P16. 3A it will be seen that flyer 46 is initiallylocated somewhere in winding relationship with coil form step 22-1,assumed to be as shown by the dashed line 206. At this point, drivemotor 26 is energized for high speed 5 operation, limit switches LS4, 5and 6 are closed, centering cylinder 158 is retracted closing limitswitch LS1, clutch coil 204 is energized, and the flyer then winds thecoil on step 22-1 at high speed, being traversed back and forth acrossstep 22-1 by the oscillatory motion of slide 72 imparted by cam 118 witha throw indicated by the arrows a.

A predetermined number of turns in advance of completion of the desirednumber of turns of the coil on step 22-1, a signal is provided acrossearly warning terminals 148 of counter 142 which energizes the operatingcoil of relay CLll, closing its contacts CL1-1 thereby sealing in theoperating coil through the normally closed time delay relay contactsTR2-1 and the stopping relay contacts RRZ-l. It will be understood thatthe early warning signal, normally appearing about three of four turnsin advance of completion of the respective coil, may occur when flyer 46is in any position in its oscillatory traversing motion a, it beingassumed in FIG. 3A that the early warning signal occurs when the flyer46 is located as shown by the dashed line 208.

Energization of relay CLl in response to the early warning signal closesits contacts CLl-2 to energize solenoid B through normally closedcontrol relay contacts CR1-1 and also to energize the operating coil oftime delay relay TRl. Energization of solenoid B retracts the level-windcylinder 126 and actuates lever 112 thereby moving cam follower roller120 away from cam 118 and moving slide 72 to its extreme rearwardposition thereby moving flyer 46 rearwardly to a point adjacent the rearedge 210 of step 22-1, as shown by the dashed line 206, the movement ofthe flyer to a point adjacent the rear edge of the step 22-1 being shownby the arrow b. Energization of the operating coil of time delay relayTRl opens its contacts TR 1-1 to deenergize the high speed contacts MHand closes its contacts TR1-2 to energize the low speed contacts ML,thus energizing the drive motor 62 for low speed operation. Flyer 46 isthus rotated at low speed during the remaining few turns of the coil onstep 22-1.

As previously indicated, main drive motor 62 is preferably a two speed,constant torque, three-phase, alternating current induction motor. In aspecific embodiment of the invention, the high speed of the flyer was2900 rpm. and the low speed was one-half of the high speed, i.e. 1450r.p.m. Such a motor is employed by reason of its extremely rapiddeceleration and acceleration between its high and low speeds, i.e. sucha motor will decelerate from its high to its low speed in about tworevolutions, and likewise accelerate from its low speed to its highspeed in about two revolutions. This rapid deceleration and accelerationis provided in such a motor by reason of the fact that when the coils ofits field winding are reconnected to provide the proper number of polesfor high speed or low speed operation, as the case may be, verysubstantial braking or accelerating torque is provided, as the case maybe, which affirmatively and positively brings the motor down to or up tothe different speed. Other types of two speed motors require asubstantially longer time for deceleration and/or acceleration from onespeed to the other.

As pointed out above, it is desired that the stepping of the block 68and the flyer 46 from one coil form step to the next be accomplishednearly instantaneously and with the flyer having a predeterminedrotational position with respect to the coil form so as to locate theintercoil connections. To this end, rectifier 212 is coupled acrossalternating current control lines 188, 190 and has its output 214coupled to direct current control lines 216, 218 through a conventionalfilter network 220 which supplies highly filtered, substantiallyripple-free direct current to direct current control lines 216, 218. Itwill now be observed that the turn completion terminals 146 of counter142 are coupled in series with the operating coil of stepping reed relayRR2 through normally closed control relay contacts CRl-3, normallyclosed relay contacts CR-6, the forward stepping commutator 134, and thenormally closed stopping reed relay contacts RR1-3. Thus, uponappearance of a turn completion signal across terminals 146 of counter142 indicating the desired number of turns have been wound on coil formstep 22-1, and when the forward stepping commutator 134 has rot-ated tocomplete the circuit through itscooperative contacts thus indicatingthat the flyer 46 is in the desiredrotational position with respect-tocoil form 22I-l, the operating coil of reed relay RR2 will be energized.Energization of reed relay RR2 closes its contacts.RR2 4- to energizesolenoid C- through normally closed control relay contacts CR4-1,. thusactuating cylinder 86 and retracting the right latch 82 to permitcylinder 78 immediately to move block 68; splined shaft 48 and flyer 46rearwardly until the left latch 84 engages abutment 88. By reason of theenergization of solenoid C with substantially ripple-free directcurrent, and the filtering of the'air supply to cylinders 87, 89,'thisretracting of the right latch 82 and the consequent rearward movementofflyer 46 by one incremental step occurs nearly'instantaneously, theflyer axially rotating less than one-quarter of a turn'duringthe'stepping operation.

Referring now briefly to FlG. 3C, retraction of the right latch 82, asabove-described and the consequent rearward movement of block 68 by oneincremental. step moves flyer 46- rearwardly from the location shown bythe dashed line206to the location shown by the dashed line 222 adjacentthe rear edge 224 of the next smaller coil form step-22-'-2.andtherefore in winding relationship therewith.

Energization of the stepping reed relay RR2 opened its contacts RR2-1 inseries with the operating coil of relay CL1,thus

breaking the sealing circuit for that relay and deenergizing relay CLl.Deenergization of relay CL1 opened its contacts CL1-2 deenergizingsolenoid B and time delay relay TRl. Deenergization of solenoid Breverses the application of air to the level-wind cylinder 126 thusagain urging actuating member 112 forwardly to urge cam follower-roller120 against cam 118 thereby to resume the oscillatory motion of slide 72to traverse flyer 46 back and forth across coil form step 22-2 with thethrow a. Deenergization of the operating coil of time delay relay TRlcloses its contacts TRl-l again to energize the high speed contacts MHand opens its contacts TR1-2 to deenergize the low speed contacts ML sothat main drive motor 62 is again energized for high speed'operation andthe flyer 46 is operated at high'speed in the forward direction to windthe next coil on coil form step 22-2 having the predeter mined number ofturns as set'in the turns counter 142.

Energization of reed relay operating coil RR2 upon completion of thefirst coil on the first coil form step 2211 closed its contacts RR2-5thus energizing the operating coil of latching relay CR3 through thenormally closed latching relay contacts CR4-3, latching relay CR3 thusbeing latched with all of its.

contacts in their actuated conditions. Upon termination of the countersignal across terminals 146, reedrelay RR2,'which was sealed in throughits contact RR2-3, is deenergized again closing its contact RRL6 toenergize latching relay .CR4 through the now-closed latching relaycontacts CR3-2, relay CR4 thus latching to its actuated position openingits contacts CR4-1 and closing its contacts CR4-2 and CR4-Silt will nowbe seen that with latching relay contact CR4-1 opened and CR4-2 closed,the next energization of the stepping reed relay RR2 closing itscontacts RR2-4 will energize the operating coil of solenoid D thereby toactuate the left latch 84.

Upon appearance of the early warning signal a predetermined number ofturns in advance of completion of the second coil on coil form step22-2, solenoid B is again actuated to retract the level-wind cylinder12650 as to move flyer.

46 to position 222 adjacent the rear end 224 of step 22-2,-as shown bythe arrow d, and main drive motor 62 is again energized from its high toits low speed operation to wind the remaining turns of the coil at lowspeed, as shown in FIG. 3D. Upon appearance of the turn completionsignal across counter terminals 146 signifying completion of the desirednumber of turns on coil form step 22-2, and upon'completion of thecircuit by the forward step commutator l34-thereby energizing reed relayRR2 and closing its contacts RR2-4, solenoid D is now energized toactuate cylinder 89 to retract the left latch 84 to permit cylinder 78to move block 68 rearwardly until the right latch.82 engages abutment90, thereby moving flyer 46 rearwardly to theposition shown by thedashed line 226 adjacent the rear edge 228 of coil form step 22-3. Sincestep 22-3 is axially shorter than steps 22-l and-22-2, the steppingdistance of block 68 and flyer 46, as indicated by the arrow edetermined by the axial spacing between abutments 88 and 90 on block 68,is shorter than the stepping distance c determined by the axial distancebetween abutments 86 and 88.

It being recalled that both control relays CR3 and CR4 are in theirlatched positions, closing of reed relay contacts RR2-5 will'energizecontrol relay CR3 to unlatch the same through the now-closed contactsCR3-1 and CR4-4, thus opening CR3-3. Closing of the reed relay contactsRR2-6 upon termination of the stepping signal will-energize controlrelay CR4 to unlatch the same through the normally closed contacts CR3-3and the still-closed contacts CR4-5. Unlatching of relay CR4 will againclose its contacts CR4-l and open its contacts CR4-2 so that the nextstepping signal signifying completion of the coil on the coil formstep22-3 will again energize solenoid C to retract the right latch 82.

Referring now-to the bottom portion of FIG. 2, with control relay CR4latched following-completion of the first coil, as above described,thenext energization of reed relay RR2 upon completion of the winding ofthe when coil form step 22-2 closing contacts RR2-7 will energizecontrol. relay .CRl3 through normally closed control relay contact'CR5-7." Solenoid 'J is simultaneously energized to extend the throwcylinder 116 thereby moving pivoted lever 104 to provide the shorterthrow for the oscillatory motion-of slide 72 during winding of the coilson the next two axially shorter coil form steps 22-3 and 22-4.Energization of control relay CRIS closes its sealing contacts CRl3-lthus scaling in relay CR13 and solenoid J.

Upon stepping of the flyer 46 to position 226 in windingrelationship'with coil form step 22 3, the solenoidB is againdeenergized toextend the level-wind cylinder 126 to resume traversing ofthe flyer with the now shorter throw f and main drive motor 62 isagainenergized for high speed operation thereby to wind the coil on coilform 22-3.at high speed, as above described. Upon occurrence of theearly warning signal across counter terminals 148 thepredetermined'number of turns in advance of completion of winding of thecoil on step 22-3, solenoid B is again energized to retractthe-level-wind cylinder 126 thereby again to shift the flyer to the rearposition 226 and the'motor is energized for low speed operation duringthe remaining turns, all as abovedescribed and as shown in FIG. 3E. Uponoccurrence of the turn completion signal across counter terminals 146signifying completion of the winding of the coil on'step 22-3 and uponcompletion of the circuit'by the forward stepping commutator l34-therebyenergizing reedrelay RR2, solenoid C is again energized to actuate"cylinder 87 to retract the right latch 82 to permit cylinder 78 to moveblock.-68 rearwardly until latch 84 engages abutment 92, thereby to stepflyer 46 rearwardly by distance e to the position as shown bythe dashedline 230 adjacent the rear end 232 of the rear coil form step 22-4, andthe winding of thecoil on that step resumes at higher speed'with thetraversing throw f as above-described.

Movement of block 68 to its rearrnost position so asrto locate flyer. 46in winding relationship with the smallest coil form step 22-4 closeslimit switch LS2 thereby energizing control relay CR1 to provide anindication that the last coil of th set is being wound. Energization ofcontrol relay -CR1 opens minal 146 signifying completion of the desirednumber of turns of the last coil being wound on coil form step 22-4. Asin the case of the previously wound coils, appearance of the earlywarning signal across early warning terminals 148 of counter 142energizes relay CLl thereby to energize the main drive motor 62 for lowspeed operation thereby rotating flyer 46 at low speed for the remainingturns of the winding on coil form step 22-4.

lt will at this point be observed that reed relays are employed for thestepping and stopping relays RR2 and RR1, reed relays being extremelyfast-acting and thus further contributing to the nearly instantaneousstepping and stopping action of the system. It will be readilyunderstood that solid state switching devices may be employed ratherthan reed relays.

Energization of the last coil control relay ClRl closes its contactsCR1-3. Upon occurrence of the turn completion signal across counterterminals 146 signifying winding of the desired number of turns of thecoil on the last coil form step 22-4, and upon completion of the circuitby the forward stopping commutator 138, the operating coil of reed relayRR1 is energized through the now closed control relay contacts CR1-2,the normally closed control relay contacts CR-4, and the normally closedrelay contacts RR2-2. Energization of the stopping reed relay RRl opensits contacts RRl-l thereby deenergizing control relay CR to open itscontacts CR1 to deenergize the clutch coil 204, and closes its contactsCR2 to energize the brake coil 202. Energization of the stopping reedrelay RRl also closes its contacts RR1-4 thereby energizing time delayrelay TR2 through the now closed CR1-3. Energization of time delay relayTR2 immediately closes its contacts TR2-2 to provide a sealing circuitthrough normally closed control relay contacts CR5-4. Energization oftime delay relay TR2 opens its contacts TRZ-l thereby to deenergize thebrake coil 202 after a short time delay and closes its time delaycontacts TR2-D2, likewise after a short time delay, to energize solenoidE so as to extend the centering cylinder 158. Upon extension of pistonrod 156 of centering cylinder 158 resulting in centering of disc 150 andflyer 46, as above described, limit switch LS3 is closed energizingsolenoid F. Energization of solenoid F reverses the air connections tocylinder 78 to extend its piston rod 80 forwardly thereby to move block68 to the extreme forward position and to return flyer 46 to itsposition in winding relationship with the forward coil form step 22-1,as shown by the arrow 1' in FIG. 3A, and as further shown in FIGS. 30and l. Return of block 68 to its forward position closes limit switchLS4 thereby energizing latching relay CR5 to its latched positionsignifying completion of one cycle of operation, i.e. the winding of oneset of coils in one direction upon coil form -1.

It is now assumed that a set of coils has previously been wound upon thecoil form 20-2 located at the unloading station during winding of theset of coils, as above-described, on the coil form 20-1 at the windingstationv Thus, the operator, may remove the coils from the coil forms atthe unloading station while the next set is being wound on the coil format the winding station. In order to remove the completed set of coilsfrom the coil form 20 at the unloading station, the operator actuatesswitch 234, which is preferably a foot-actuated switch, therebyenergizing solenoid G to extend coil form collapsing cylinder 42 therebycollapsing the coil form 20-2 at the unloading station by moving itslower part 36 upwardly toward its upper part 34 against spring 38.Collapse of the coil form at the unloading station moves limit switchLS5 to its collapsed" position thereby energizing control relay C R6through normally closed contacts C R7-1, energization of control relayCR6 closing its contacts CR6-1 to provide a sealing circuit. When theoperator has completed removal of the coil from the collapsed coil form20-2 at the unloading station, switch 234 is released thus deenergizingsolenoid G to retract the form collapsing cylinder 42 and permitting thelower coil form part 36 to return to its expanded position under theinfluence of spring 38. Return of the coil form collapsing cylinder 42to its retracted position returns limit switch LS5 to its retracted"position thus energizing and latching relay CR7 through the now-closedcontrol relay contacts CR6-2.

Assuming that the tape ejection cylinder 182 is extended, thus extendingrack 180 so that limit switch LS6 is closed, with the control relaycontacts C R7-2 now closed in response to collapse and subsequentexpansion of the respective coil form indicating removal of the coilstherefrom, when latching relay contacts CR5-5 close, as above-described,signifying completion of the cycle, the operating coil M1 for indexdrive motor 32 is energized through the normally closed control relaycontacts CR1 1-1 and CRB-l, thus energizing the index motor 32 to indexor rotate the coil forms to move coil form 20-1 upon which a completeset of coils has been wound to the unloading station and to move coilform 20-2 from which the set of coils has just been removed to thetape-applying station. Rotation of index cam 44 immediately opens limitswitch contacts LS7-1 which close when the coil forms have been indexedby and again properly positioned at their respective stations, closingof limit switch contacts LS7-1 energizing control relay CR8 closing itssealing contacts CR8-2 and opening its contacts CR8-1 to deenergizc theindex motor contacts Ml. Thus, it is seen, that the coil forms 20 cannotbe indexed until the coil form at the unloading station has beencollapsed and extended, signifying removal of the set of coilstherefrom.

Rotation of index cam 44 to a position indicating proper locating of thecoil forms also closes limit switch contact LS7-2 energizing time delayrelay TR4 through the nowclosed control relay contacts CR8-3.Energization of time delay relay TR4 closes its contacts CR4-l tounlatch control relay CR5 and also closes its contacts CR4-2 to unlatchcontrol relay CR7. Unlatching of control relay CR5 and CR7 open theircontacts CRS-S and CR7-2 thereby deenergizing control relay CR8 openingits contacts CR8-3 to deenergize time delay relay TR4. Deenergization oftime delay relay TR4 immediately closes its contacts TR4-3 to energizethe automatic restarting control relay CR9, time delay contacts TR4-Dopening after a predetermined time delay to deenergize control relayCR9. Energization of control relay CR9 closes its contacts CR9-1 inparallel with the START-2 switch contacts, thus commencing a new cycleof operation, as above-described.

Indexing of the coil form assembly 14 by 90 rotates cam 160 by thatamount closing limit switch LS8 to energize control relay CR10.Energization of control relay CR10 opens its contacts CR10-1 and closesits contacts CR10-2 to deenergize the forward motor contacts MF andenergize the reverse motor contacts MR. Energization of control relayCR10 also closes its contacts CR10-3 and CR10-5, and opens its contactsCR10-4 and CR10-6 to render the reverse stopping and steppingcommutators and 136 effective, and to disable the forward stopping andstepping commutators 138 and 134.

It will be observed that a manually actuated indexing switch 236 isprovided for energizing the index contacts M1 as desired.

1n the particular illustrated embodiment, it is desired that the tapeejection mechanism 16 be actuated upon completion of the winding ofthree of the four coils being wound at the winding station, provided theoperator has already removed the previously wound coils from the coilform at the unloading station, as signified by collapse and subsequentexpansion of the coil form, or alternatively during removal of the coilsfrom the coil form at the unloading station if that operation has notbeen accomplished during winding of the new set of coils. Further, it isnecessary to terminate the application of vacuum to the channels 164 andslots 162 in order to permit application of a new length of tape to thecoil form 20-3 at the tape applying station, however, it is desired thatvacuum be applied to all of the coil forms, other than the coil form20-2 at the unloading station, at least until three of the four coilshave been wound on the coil form 20-1 at the winding station.Energization of solenoid l actuates the vacuum valve to apply vacuum tothe channels 164 and slots 162 and thus, control relay 12 and solenoid Iare normally energized through the normally closed control relaycontacts CR1-5 and the sealing contacts CR12-2, energization of controlrelay CR12 opening its contacts CR12-1 in series with solenoid H whichwhenenergized retracts the tape ejection cylinder 182.

Thus, assuming the situation where the'coils have already been removedby the operator from the coil form 20-2 at the unloading station priorto completion of the winding of the set of coils on the coil form 20-1at the winding station, control relay contact CR7-3 will be closed inresponse to collapse and subsequent expansion of the coil 'fonn 20-2.Movement of block 68 to its rearmost position thus opening limit switchLS2 energizes control relay CRl closing its contacts CR1-4 and openingits contacts CR1-5 thereby deenergizing control relay 12 and solenoid Ito terminate the application of the vacuum, contacts CR12-1 in serieswith solenoid H closing. Limit switch LS9 is normally open, being closedwhen the tape ejection cylinder 182 and rack 180 are retracted. Thus,appearance of the early warning signal for the last coil which causesenergization of time delay relay TRI, as above 170 into the slot 162 ofthe coil form 20-3 at the tape applying station. Energization of controlrelay CRll closes its sealing contacts CR1 l-1. Retraction of the tape,ejection cylinder 182 to the rearmost position of rack 180 closes limitswitch LS9 again to energize control relay CR12 and solenoid I, therebyagain applying vacuum to retain the newly applied tape, energization ofcontrol relay CR12 opening its contacts CR12-l to deenergize solenoid Hthus to extend tape ejection cylinder 182 and rack 180. Extension oftape ejection cylinder 182 and rack 180 again opens limit switch LS9,however it being recalled that the tape ejection process started noearlier than the early warning signal for the last coil which precedesthe tum completion signal for the last by only a few revolutions of theflyer 46, by the time the tape cylinder 182 is extended to open limitswitch LS9, block 68 has been returned to its forward position thusopening limit switch LS2 and deenergizing control relay CR1 therebyclosing contacts CR1-S so that control relay 12 is now sealed-in throughits own contact CR12-2.

In the alternative situation, i.e. in which the coils have not beenremoved from the coil form 20-2 at'the unloading station prior to thecompletion of winding of the set of coils on the coil form 20-1 at thewinding station, latching relay contacts CR5-6 will close uponcompletion of the cycle, as abovedescribed, and upon actuation of thecoil form collapse switch 234 with the result of closing of controlrelay contacts CR6-3, CRll and solenoid H will again be energized, asabove described. A manually actuated switch 236 is provided for manualejection of tape when desired.

Extension of the tape ejection cylinder 182 and rack 180 closes limitswitch LS6, and deenergization of control relay- CR11 responsive tounlatching of control relay CR7 together with deenergization of controlrelay CR6, thus opening their contacts CR7-3 and CR6-3, results inclosing of control relay contacts CRl1-1 thus permitting the nextenergization of index motor contact MI.

Inspection of FIG. 3G,. H and I will now indicate that vacuum is appliedto all of the coil forms, with the exception of the coil form at theunloading station, until appearance of the last coil signal responsiveto movement of the block 68 to its rearrnost position. Upon appearanceof the early warning signal, and provided that the coils have alreadybeen removed from the coil form at the unloading station, tape ejectionmechanism 16 is actuated to apply tape to the coil format the tapeapplying station. Upon appearance of the turn completion signal for thelast coil being wound at the winding station, the clutch is deenergizedand the brake is energized, the centering cylinder 158 is extended, theblock 68 and flyer 46 are returned to the forward position and uponreturn, vacuum is again applied in response to extension of the tapeejection cylinder 182. With a complete set of coils thus wound on the 75tion Ser. No. 842,567, filed July I7, 1969 ofthe present inventor,likewise assigned to the Assignee of the present application.

Referring now to FIG. 4, another embodiment is shown, with like elementsbeing indicated by like reference numerals,

in which slide 72' rather than being oscillated with throwscorresponding to the length of the respective coil form steps 22 therebyto level-wind the coils on the respective coil form steps, iscontinuously traversed from an extreme forward position, as shown inFIG. 4, to a rearward position as shown by the dashed line 240, by alead screw 242, thereby to traverse the flyer 46 (not shown in FIG. 4)from the forward end of the largest coil form step 22-1 to the rear endof the smallest coil form step 22-4'- so as to single layer-wind thecoils upon the coil form steps. Thus, in this embodiment, the level-windmechanism 102 of the embodiment of FIG. 1 is'eliminated in its entirety.Further, for simplicity, the tape ejection mechanism 16 of theembodiment of FIG. 1 is not shown, it being understood that the tapeejection mechanism may not necessarily be included with eitherembodiment.

Referring additionally to FIG. 6A, in this embodiment, with block 68inits forward position actuating limit switch LS4, and with slide 72 inits forward position actuating limit switch- L812, flyer 46 will bepositioned in winding relationship adjacent the forward end of the firstcoil form step 224', as

shown by the dashed line 244. A half-nut 246 is pivotally mounted onbracket 248 attached to slide 72 for selectively engagingand'disengaging lead screw 242. Half-nut 246 is actuated to itsdisengaged position by pneumatic cylinder 250 actuated by a solenoidvalve, identified as solenoid K. A limit switch, identified as LS1 1,senses engagement and disengagement of half-nut 246 with the screw 242.Half-nut 246 is returned to its engaged position upon deenergization ofsolenoid K and deactuation of cylinder 250 by a suitable spring 252.

Lead screw 242 is driven in one direction so as to move slide 72'together with block 68', splined shaft 48 and flyer 46'rearwardly in thedirection shown by the arrow 254, when half-nut 246 is engaged with leadscrew 242, by a conventional one way drive mechanism 256, in turn drivenby a variable speed drive mechanism 258 from drive shaft 60. Thus, withblock 68' and slide 72 respectively in their forward positions, thuslocating flyer 46 at its initial position 244 in winding relationshipwith the forward end of the largest coil form step 22-1', andwith'half-nut 246 engaging lead screw 242, energization of the clutchportion of clutch-brake 64 will cause rotation of the flyer at highspeed and movement of slide 72 in the direction shown bythe arrow 254 bylead screw 242.

Winding thus proceeds at high speed in'one direction until appearance ofthe early warning signal, as'above-described, a predetermined number ofturns advance of completion of the winding of the coils on the firstcoil form step 22-1. Upon occurrence of the early warning signal, themain drive motor 62 is actuated to low speed and upon occurrence of theturn completion signal, and with the flyer 46 properly rotationallypositioned with respect to the coil form 20-1, the right latch 82 isactuated so that block 68', splined shaft 48 and flyer 46 are movedrearwardly by cylinder 78 until latch 84-engages abutment 88', thusmoving flyer 46 by one incremental step, as shown by the arrow b fromits final position adjacent end 210 of the first coil form step 22, asshown by the dashed line 260, to an initial position adjacent theforward endofthe next coil form step 22', as shown by the dashed line262. It-will be readily seenthatthe location of the finishing end of thefirst

1. Apparatus for automatically winding a set of at least two concentricdynamoelectric machine coils comprising: a coil form having spacedopposite ends with at least two progressively smaller steps extendingtherebetween: a flyer mounted on a shaft for winding a wire on said coilform steps to form said coils; first means for rotatably supporting saidshaft; an electric motor providing at least two speeds coupled to saidshaft for rotating the same and said flyer; a control circuit includingfirst control means for selectively energizing said motor for high andlow speed operation; second means for supporting said first supportmeans for longitudinal movement parallel with the axis of said shaft;first means on said second support means and operatively connected tosaid first support means for selectively sequentially moving said firstsupport means, shaft and flyer from a forward to a rear position in atleast one incremental step thereby respectively to position said flyerin winding relationship with said coil form steps; second meansoperatively coupling said motor to said second support means for movingthe same and said first support means, shaft and flyer longitudinallyparallel with the axis of said shaft thereby to traverse said flyer withrespect to said coil form; means for selectively positioning said firstsupport means, shaft and flyer at an initial location with said firstsUpport means in said forward position and with said flyer in windingrelationship with a first coil form step adjacent one end of said coilform; means for counting the number of revolutions of said shaft andflyer; means for initially actuating said first control means toenergize said motor for high speed operation thereby to wind a firstcoil on said first coil step at high speed; said control circuit furtherincluding second control means responsive to said counting means foractuating said first control means to energize said motor for low speedoperation in response to winding a first predetermined number of turnsof said first coil, and third control means responsive to said countingmeans for actuating said first moving means to move said first supportmeans, shaft and flyer by a first said incremental step from saidforward position to a second position with said flyer located in windingrelationship with a second coil form step adjacent said first coil formstep in response to a second coil form step adjacent said first coilform step in response to a second predetermined number of turns of saidfirst coil greater than said first number corresponding to completion ofsaid first coil; said third control means being coupled to said firstcontrol means and actuating the same to energize said motor for highspeed operation in response to said second number thereby to initiatewinding of a second coil on said second coil form step at high speed. 2.The apparatus of claim 1 wherein said motor is a multiphase, alternatingcurrent induction motor thereby providing rapid deceleration from saidhigh to said low speed, said motor providing substantially constantspeed operation of said flyer at said low speed.
 3. The apparatus ofclaim 2 wherein said motor is of the constant torque type.
 4. Theapparatus of claim 1 wherein said first moving means includes means fornormally biasing said first support means toward said rear position,selectively actuable latching means for retaining said first supportmeans at said forward position and at least at said second position, andmeans including electromagnetic means for actuating said latching meansthereby permitting said biasing means to move said first support meansrearwardly by one said incremental step to the next position, said thirdcontrol means including a source of electric current and means forselectively energizing said electromagnetic means thereby.
 5. Theapparatus of claim 4 wherein said electromagnetic means includes atleast one reed relay, and wherein said source provides substantiallyripple-free direct current for energizing said reed relay.
 6. Theapparatus of claim 5 wherein said actuating means includes a pneumaticcylinder operatively connected to said latching means and having an airline for supplying a actuating air thereto, said electromagnetic meansfurther including a solenoid valve in said air line, said valve beingenergized from a source of direct current, and further comprising meansfor filtering the air supplied to said solenoid valve and cylinder toremove oil and moisture therefrom.
 7. The apparatus of claim 4 whereinsaid control circuit includes fourth control means operatively driven bysaid motor in synchronism with said shaft and flyer for sensing apredetermined rotational position of said flyer with respect to saidcoil form, said third control means including means responsive to saidfourth control for energizing said electromagnetic means whereby saidfirst support means, shaft and flyer are moved to said second positionin response to said second number only when said flyer is in saidpredetermined rotational position.
 8. The apparatus of claim 7 whereinsaid fourth control means includes a commutator and cooperative contactswhich complete a circuit for energizing said electromagnetic means whensaid flyer is in said predetermined rotational position.
 9. Theapparatus of claim 1 wherein said control circuit includes clutch meansfor selectively starting and sTopping said shaft and flyer, fourthcontrol means responsive to said counting means for actuating saidclutch means to stop said shaft in response to winding a predeterminednumber of turns of the last coil of said set on the coil form stepadjacent the other end of said coil form, said fourth control meansactuating said positioning means to return said first support means,shaft and flyer to said initial location, and fifth control means foractuating said clutch means and first control means to start said shaftand to energize said motor at high speed in response to return of saidfirst support means to said initial location thereby to initiate windingof a new set of coils on said coil form.
 10. The apparatus of claim 9wherein said control circuit includes sixth control means operativelydriven by said motor in synchronism with said shaft and flyer forsensing a predetermined rotational position of said flyer with respectto said coil form, said fourth control means including means responsiveto said sixth control means for actuating said clutch means to stop saidshaft in response to said last-named number only when said flyer is insaid predetermined rotational position.
 11. The apparatus of claim 10wherein said sixth control means includes a commutator and cooperativecontacts which complete a circuit for actuating said clutch means whensaid flyer is in said predetermined rotational position.
 12. Theapparatus of claim 9 wherein said motor is reversible, said controlcircuit including sixth control means for selectively reversing thedirection of rotation of said motor, said initial actuating meansactuating said sixth control means for operation of said motor in onedirection, said fifth control means actuating said sixth control meansto reverse said motor whereby said new set of coils is wound in theopposite direction.
 13. The apparatus of claim 9 further comprising atleast a second coil form identical to said first-named coil form andradially spaced therefrom, means for selectively indexing said coilforms between at least winding and unloading stations, each of said coilforms being collapsible to permit removal of the set of coils woundthereon, means at said unloading station for selectively actuating therespective coil forms between collapsed and expanded position; saidcontrol circuit including sixth control means for actuating saidindexing means thereby to move one of coil forms to said unloadingstation and another coil form to said winding station in response to oneof said fourth and fifth control means, and seventh control meansincluding means for inhibiting actuation of said indexing means whensaid coil form at said unloading station is in its collapsed positionand means for inhibiting said first control means when said coil formsare removed from said winding and unloading stations, respectively. 14.The apparatus of claim 13 wherein each of said coil forms includes meansfor receiving a length of adhesive tape for retaining the turns of thecoils of a set, each of said coil forms having a vacuum conduitcommunicating with said receiving means, and further comprising a supplyof adhesive tape, means at a station other than said winding station forselectively withdrawing a predetermined length of tape from said supplyand positioning the same in said receiving means of the respective coilform, a vacuum line for applying a vacuum to said conduits thereby toretain the length of tape in the respective receiving means, means forinhibiting application of vacuum to the coil form at said unloadingstation, and valve means in said vacuum line for selectively opening andclosing the same; said control circuit including eighth control meansincluding means for actuating said valve means to close said vacuum lineand for actuating said withdrawing means to position a length of tape inthe receiving means of the respective coil form, means for inhibitingactuation of said valve and withdrawing means prior to winding at leasta part of the coIls of the set being wound at the coil form at saidwinding station, means for actuating said valve means to open saidvacuum line in response to positioning a length of tape in therespective receiving means, and means for inhibiting actuation of saidwinding means prior to withdrawal and positioning of said length of tapein the respective receiving means.
 15. The apparatus of claim 9 furthercomprising means for selectively rotationally positioning said shaft andflyer to have a predetermined rotational relationship with said coilform; one of forth and fifth control means actuating said last-namedpositioning means.
 16. The apparatus of claim 1 wherein said motor ismultiphase, constant torque, alternating current induction motor therebyproviding rapid deceleration from said high to said low speed; saidfirst moving means including means for normally biasing said firstsupport means toward said rear position, selectively actuable latchingmeans for retaining said first support means at said forward positionand at least at a second position spaced from said first position bysaid first incremental step, and means including a reed relay foractuating said latching means thereby permitting said biasing means tomove said first support means rearwardly by one said incremental step tothe next position; and further comprising a source of substantiallyripple free direct current; said control circuit including fourthcontrol means operatively driven by said shaft in synchronism with saidshaft and flyer for sensing a predetermined stepping rotational positionof said flyer with respect to said coil form, said third control meansincluding means responsive to both said counting means and to saidfourth control means for energizing said reed relay from said sourcewhereby said first support means, shaft and flyer are moved to saidsecond position in response to said second number only when said flyeris in said predetermined stepping rotational position; said controlcircuit including clutch means for selectively starting and stoppingsaid shaft and flyer, said clutch means including a second reed relayfor actuating the same, fifth control means operatively driven by saidmotor in synchronism with said shaft and flyer for sensing apredetermined stopping rotational position of said flyer for sensing apredetermined stopping rotational position of said flyer with respect tosaid coil form, sixth control means responsive to both said countingmeans and to said fifth control means for energizing said second reedrelay from said source thereby to actuate said clutch means to stop saidshaft in response to winding a predetermined number of turns of the lastcoil of said set on the coil form step adjacent the other end of thecoil form when said flyer is in said predetermined stopping rotationalposition; said sixth control means actuating said positioning means toreturn said first support means, shaft and flyer to said initiallocation, and seventh control means for actuating said fourth and firstcontrol means to start said shaft and to energize said motor at highspeed in response to return of said first support means to said initiallocation thereby to initiate winding of a new set of coils on said coilform.
 17. The apparatus of claim 1 wherein said coil form includes atleast one step having a first axial length and at least one other stephaving a second axial length, said second coupling means including meansfor oscillating said second support means and said first support means,shaft and flyer with first and second throws respectively generallycorresponding to said first and second lengths thereby to level-windcoils on said steps, and means for selectively shifting said oscillatingmeans between said first and second throws; said third control meansincluding means for actuating said shifting means to shift said couplingmeans from said first to said second throws with movement of said firstsupport means, shaft and flyer by a said incremental step from windingrelatIonship with a coil form step having said first length to windingrelationship with a coil form step having said second length.
 18. Theapparatus of claim 1 wherein said second support means is axiallymovable between forward and rear positions, said second support meansbeing in said forward position when said first support means, shaft andflyer are at said initial location, said first support means, shaft andflyer are at said initial location shaft and flyer having a finallocation with said first and second support means respectively in saidrear position thereof and with said flyer in winding relationship with alast coil form step adjacent the other end of said coil form; saidsecond moving means including a lead screw, drive means for operativelyconnecting said lead screw to said motor, and means connected to saidsecond support means for selectively engaging and disengaging said leadscrew, said lead screw with said engaging means engaged therewithcontinuously moving said second support means from said forward to saidrear position thereof, thereby moving said first support means, shaftand flyer to traverse said flyer from one end to the other end of saidcoil form; said control circuit including fourth control meansresponsive to said counting means for actuating said engaging means todisengage said lead screw in response to winding a predetermined numberof turns of the last coil of said set on said last coil form step; saidpositioning means including third means for selectively moving saidsecond support means and said first support means, shaft and flyer fromsaid rear position to said forward position of said second supportmeans, said first moving means being arranged selectively to move saidfirst support means, shaft and flyer from said rear position to saidforward position of said first support means, said fourth control meansactuating said third moving means to return said second support means tosaid forward position; said control circuit including fifth controlmeans for actuating said engaging means to reengage the same with saidlead screw when at least said second support means is in said forwardposition, one of said fourth and fifth control means actuating saidfirst moving means to return said first support means to said forwardposition.
 19. The apparatus of claim 18 wherein said drive means includemeans for selectively connecting said lead screw to said motor, saidfourth control means including means for actuating said connecting meansto disconnect said lead screw from said motor thereby to stop said leadscrew; said control circuit including sixth control means for sensing apredetermined rotational position of said lead screw with respect tosaid engaging means, and means for selectively rotating said lead screw,independently of said drive means; said fourth control means actuatingsaid rotating means to rotate said lead screw is in said position, saidfifth control means actuating said engaging means to reengage said leadscrew in response to said sixth control means whereby said lead screw isreengaged only when the same is in said position; said control circuitincluding seventh control means for actuating said drive means toreconnect said lead screw to said motor in response to reengagement ofsaid engaging means with said lead screw and return of said firstsupport means to said forward position thereby to initiate winding a newset of coils on said coil form.
 20. The apparatus of claim 19 whereinsaid sensing means includes a commutator operatively driven by said leadscrew and cooperating contacts which complete a circuit when said leadscrew is in said predetermined rotational position thereby to actuatesaid engaging means to reengage sad lead screw.